The belt conveyor roller fault monitoring based on manual inspection and vibration signal diagnosis cannot guarantee high reliability and real-time performance. Therefore, power line carrier communication is used to transmit belt conveyor roller operation data. The traditional power line carrier communication is intrusive and requires regular battery replacement. In order to solve the above problems, a mine belt conveyor roller operation condition monitoring system based on self-powered and non-intrusive power line carrier communication is proposed. The system consists of transmitter, receiver and 127 V lighting power line. The transmitter is installed at the belt conveyor rollers, and FPGA is used as the core controller to collect and modulate the audio signals that generated during the operation of the rollers into high-frequency signals. The high-frequency signal is coupled into the lighting power line through an inductive coupler so as to realize non-intrusive power line carrier communication. The receiver is installed in the ground control room to realize the decoupling, demodulation, and restoration of the signal in the lighting power line. Pearson correlation coefficient analysis is performed on the collected original audio signal and the restored audio signal. After confirming the accuracy of the restored audio signal, the cepstral analysis is performed so as to judge the fault of the rollers. The experimental results show that the system can accurately diagnose the fault of belt conveyor rollers.
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